Thermal flow meter having seal areas with deformed ferrules

ABSTRACT

Provided is a thermal flow meter including an inlet-side body into which an inlet of a measurement tube is inserted, an outlet-side body into which an outlet of the measurement tube is inserted, an inlet-side nut having internal threads fastened to external threads formed on the inlet-side body, an outlet-side nut having internal threads fastened to external threads formed on the outlet-side body, an inlet-side ferrule of resin being deformed to form a seal area as the inlet-side nut  15   a  is fastened to the inlet-side body, and an outlet-side ferrule of resin being deformed to form a seal area as the outlet-side nut is fastened to the outlet-side body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Application No. 2015-033221, the contents of which are incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to a thermal flow meter.

BACKGROUND ART

Thermal flow meters are known in the art chat control the temperature of liquid flowing through the flow passage to measure a flow rate based on a difference between temperatures of the liquid upstream and downstream of the temperature control part (refer to Japanese Unexamined Patent Application, Publication No. 2006-10322, for example).

Japanese Unexamined Patent Application, Publication No. 2006-10322 discloses a thermal flow meter with a flow passage a wetted portion of which is entirely formed of glass that is obtained by forming a rectangular groove on a glass substrate and bonding another glass substrate with a heat transfer means and a temperature detecting means to the groove side of the earlier glass substrate.

CITATION LIST Patent Literature

{PTL 1}

Japanese Unexamined Patent Application, Publication No. 2006-10322

SUMMARY Technical Problem

The thermal flow meter desirably includes a tubular measurement tube with a straight tube portion extending linearly when measuring a very small amount of flow rate (e.g., 0.1 cc/min to 30 cc/min). The inclusion of the tubular measurement tube with the straight tube portion enables rectifying flow of liquid to stably send the liquid to the temperature detecting means. Moreover, the liquid is replaced with another liquid well without any bubbles remaining on the flow passage to have enhanced liquid replacement property. Furthermore, the measurement tube, which has a relatively simple shape, can be manufactured at a low cost as well as promoting ease of assembly.

When including the tubular measurement tube with the straight tube portion, however, it is required to securely fix both end portions of the measurement tube with a small diameter and to suppress leakage of the liquid at the both ends of the measurement tube.

The present disclosure has been made in view of the circumstances, and aims to provide a thermal flow meter in which the both end portions of the measurement tube are securely fixed and which can suppress the leakage of the liquid at the both ends of the measurement tube.

Solution to Problem

In order to solve the foregoing problem, the following solutions have been adopted in the present disclosure.

A thermal flow meter according to an aspect of the present disclosure includes a measurement tube including an inlet through which liquid enters and an outlet through which the liquid flowing from the inlet exits, and having an internal flow passage extending along an axis, a temperature detecting substrate having a heating resistance element and a temperature detecting resistance element formed on a detection surface thereof along the axis, the detection surface being bonded to the measurement tube along the axis, an inlet-side body which has inside a first connection flow passage and into which the inlet of the measurement tube is inserted, an outlet-side body which has inside a second connection flow passage and into which the outlet of the measurement tube is inserted, a cylindrical inlet-side nut fitted along an outer circumferential surface of the measurement tube to be closer to the outlet than the inlet-side body, the inlet-side nut having on an inner circumferential surface thereof internal threads fastened to external threads formed on an outer circumferential surface of the inlet-side body, a cylindrical outlet-side nut fitted along the outer circumferential surface of the measurement tube to be closer to the inlet than the outlet-side body, the outlet-side nut having on an inner circumferential surface thereof internal threads fastened to external threads formed on an outer circumferential surface of the outlet-side body, an inlet-side ferrule of resin formed in a cylindrical shape and fitted between the outer circumferential surface of the measurement tube and an inner circumferential surface of an end portion of the inlet-side body facing the outlet, the inlet-side ferrule being deformed to form a seal area as the inlet-side nut is fastened to the inlet-side body, and an outlet-side ferrule of resin formed in a cylindrical shape and fitted between the outer circumferential surface of the measurement tube and an inner circumferential surface of an end portion of the outlet-side body facing the inlet, the outlet-side ferrule being deformed to form a seal area as the outlet-side nut is fastened to the outlet-side body.

According to a thermal flow meter in an aspect of the present disclosure, the inlet of the measurement tube with the detection surface of the temperature detecting substrate bonded thereto is inserted into the inlet-side body and connected to the first connection flow passage formed inside the inlet-side body. Similarly, the outlet of the measurement tube is inserted into the outlet-side body and connected to the second connection flow passage formed inside the outlet-side body.

When the external threads formed on the outer circumferential surface of the inlet-side body are fastened to the internal threads formed on the inner circumferential surface of the inlet-side nut, the inlet side end portion of the measurement tube is fixed, and at the same time, the cylindrical inlet-side ferrule that is fitted around the outer circumferential surface of the measurement tube is deformed to form the seal area. Similarly, when the external threads formed on the outer circumferential surface of the outlet-side body are fastened to the internal threads formed on the inner circumferential surface of the outlet-side nut, the outlet side end portion of the measurement tube is fixed, and at the same time, the cylindrical outlet-side ferrule that is fitted around the outer circumferential surface of the measurement tube is deformed to form the seal area.

The formation of the seal area on the inlet side of the measurement tube prevents the liquid from flowing out through the location of connection of the internal flow passage of the measurement tube with the first connection flow passage of the inlet-side body. Similarly, the formation of the seal area on the outlet side of the measurement tube prevents the liquid from flowing out through the location of connection of the internal flow passage of the measurement tube with the second connection flow passage of the outlet-side body.

Thus, according to a thermal flow meter in an aspect of the present disclosure, there can be provided the thermal flow meter in which the both end portions of the measurement tube are securely fixed and which can suppress the leakage of the liquid at the both ends of the measurement tube.

A thermal flow meter according to an aspect of the present disclosure may be configured such that an end portion of the inlet-side nut facing the outlet is provided with a first recess into which an end portion of the temperature detecting substrate facing the inlet is inserted, the end portion of the temperature detecting substrate facing the inlet is fixed to the inlet-side nut by a filler charged in the first recess, an end portion of the outlet-side nut facing the inlet is provided with a second recess into which an end portion of the temperature detecting substrate facing the outlet is inserted, and the end portion of the temperature detecting substrate facing the outlet is fixed to the outlet-side nut by a filler charged in the second recess.

With this configuration, the end portion of the temperature detecting substrate facing the inlet is fixed, by the filler, inside the first recess of the inlet-side nut, and the end portion of the temperature detecting substrate facing the outlet is fixed, by the filler, inside the second recess of the outlet-side nut. This can securely fix the both end portions of the measurement tube to the inlet-side nut and the outlet-side nut.

A thermal flow meter according to an aspect of the present disclosure is configured such that the measurement tube has on an outer circumferential surface thereof a flat surface on which the detection surface of the temperature detecting substrate is oppositely positioned, and the flat surface and the detection surface of the temperature detecting: substrate are bonded together with an adhesive.

This enhances the adhesiveness of the temperature detecting substrate to the measurement tube while reducing the amount of the adhesive required for the adhesion.

In a thermal flow meter in accordance with an aspect of the present disclosure, a first distance from the detection surface of the temperature detecting substrate to an inner circumferential surface of the internal flow passage may be shorter than a second distance from a top portion of the measurement tube to the inner circumferential surface of the internal flow passage.

This can enhance the property of the heating resistance element to heat the liquid inside the internal flow passage and the property of the temperature detecting resistance element to detect the temperature of the liquid.

In a thermal flow meter in accordance with an aspect of the present disclosure, the temperature detecting substrate and the measurement tube may be made of glass.

Using the temperature detecting substrate and the measurement tube which have excellent heat resistance and less probability of deformation by heat, the flow rate measurement accuracy can be maintained regardless of changes in temperature. In addition, because the materials with the same thermal conductivity properties are bonded together, the adhesiveness of the temperature detecting substrate to the measurement tube can be maintained regardless of changes in temperature.

Advantageous Effects

The present disclosure can provide a thermal flow meter in which both end portions of a measurement tube are securely fixed and which can suppress leakage of the liquid at both ends of the measurement tube.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a vertical cross-sectional view of a thermal flow meter according to a first embodiment;

FIG. 2 is an exploded assembly view of the thermal flow meter shown in FIG. 1;

FIG. 3 is a vertical cross-sectional view illustrating a sensor unit, shown in FIG. 2;

FIG. 4 is an exploded assembly view of the sensor unit shown in FIG. 3;

FIG. 5A illustrates a plan view of a measurement tube, a sensor substrate, and a reinforcing plate shown in FIG. 3;

FIG. 5B illustrates a vertical cross-sectional view of a measurement tube, a sensor substrate, and a reinforcing plate shown in FIG. 3;

FIG. 5C illustrates a bottom view of a measurement tube, a sensor substrate, and a reinforcing plate shown in FIG. 3;

FIG. 6 is a cross-sectional view of the sensor unit shown in FIG. 3 taken along the line A-A;

FIG. 7 is a cross-sectional view of the measurement tube, the sensor substrate, and the reinforcing plate shown in FIG. 5B taken along the line B-B;

FIG. 8 is a plan view of a detection surface of the sensor substrate shown in FIG. 5B;

FIG. 9 is a vertical cross-sectional view of the sensor unit of the thermal flow meter according to a second embodiment; and

FIG. 10 is an elevational view of a guide shown in FIG. 9.

DESCRIPTION OF EMBODIMENTS

{First Embodiment}

Hereinafter, a thermal flow meter 100 according to a first embodiment of the present disclosure will be described with reference to the drawings.

The thermal flow meter 100 of the embodiment heats liquid flowing through an internal flow passage and detects a temperature of the heated liquid to thereby measure a flow rate thereof. The thermal flow meter 100 of the embodiment is suitable for measuring a very small amount of flow rate in the range of from 0.1 cc/min to 30 cc/min, for example.

As shown in FIGS. 1 and 2, the thermal flow meter 100 of the embodiment includes a sensor unit 10, a control substrate 20, a relay substrate 30, an upper case 40, and a bottom case 50.

As shown in FIG. 3, the sensor unit 10 lets incoming liquid from an inlet 10 a connected to external piping (not shown) flow out through an outlet 10 b connected to external piping (not shown), and at the same time, measures a flow rate of the liquid flowing through an internal flow passage 10 c. The sensor unit 10 does not directly calculate the flow rate of the liquid, but detects the temperature of the liquid heated by a heating resistance wire 12 a (a heating resistance element) that will be described later with temperature detecting resistance wires 12 b and 12 c (temperature detecting resistance elements), and transmits a temperature detection signal indicating the detected, temperature to the control, substrate 20 through a signal wire (not shown).

The sensor unit 10 will, be described later in detail.

The control substrate 20 transmits a voltage signal to the heating resistance wire 12 a of the sensor unit 10 to heat it, and also calculates the flow rate of the liquid based on the temperature transmitted from the temperature detecting resistance wires 12 b and 12 c.

The relay substrate 30 that relays various signals transmitted and received between the control substrate 20 and an external device (not shown). A cable 200 for transmitting and receiving the various signals to and from the external device (not shown) is connected to the relay substrate 30.

The upper case 40 serves as a housing for an upper portion of the thermal flow meter 100, and accommodates the control substrate 20 inside.

The bottom case 50 serves as a housing for a lower portion of the thermal flow meter 100, and accommodate the sensor unit 10 inside. With the sensor unit 10 inserted in the bottom case 50, a stopper 60 is inserted between the bottom case 50 and the sensor unit 10 from the inlet 10 a side of the sensor unit 10.

Similarly, with the sensor unit 10 inserted in the bottom case 50, a stopper 70 is inserted between the bottom case 50 and the sensor unit 10 from the outlet 10 b side of the sensor unit 10. The sensor unit 10 becomes fixed to the bottom case 50 by means of the stoppers 60 and 70.

The bottom case 50 has fastening holes 50 a on its bottom surface and is fixed to an installation surface (not shown) by fastening bolts (not shown) that are inserted from below the installation surface.

Next, the sensor unit 10 will be described in detail with reference to FIGS. 3 to 8.

As shown in FIGS. 3 and 4, the sensor unit 10 has a measurement tube 11, a sensor substrate 12 (temperature detecting substrate), a reinforcing plate 13, a guide 14, a nut 15, an inlet-side body 16, an outlet-side body 17, an inlet-side ferrule 18, and an outlet-side ferrule 19.

The measurement tube 11 is a tube that includes an inlet 11 a through which liquid enters and an outlet 11 b through which the liquid from the inlet 11 a exits. As shown in FIG. 6 (a cross-sectional view taken along the line A-A in FIG. 3), the measurement tube 11 has formed therein the internal flow passage 10 c that extends along an axis X and has a circular cross section. The measurement tube 11 is formed of a resin material with high corrosion resistance to alkaline liquids (e.g., PTFE: polytetrafluoroethylene).

As shown in FIG. 8, the sensor substrate 12 is a glass substrate (e.g., made of quarts glass, which has a high silicon dioxide content) with the heating resistance wire 12 a (the heating resistance element), the temperature detecting resistance wire 12 b (the temperature detecting resistance element), and the temperature detecting resistance wire 12 c (the temperature detecting resistance element) formed on a detection surface 12 d along the axis X.

The heating resistance wire 12 a, the temperature detecting resistance wire 12 b, and the temperature detecting resistance wire 12 c are each formed of a metal film, such as of platinum, evaporated onto the glass substrate.

The liquid flowing in the measurement tube 11 flows along the axis X from the left to the right in FIG. 8. Accordingly, when the heating resistance wire 12 a is heated momentarily, the heated liquid flows along the axis X to the position of the temperature detecting resistance wire 12 b and then to the temperature detecting resistance wire 12 c.

The control substrate 20, therefore, can calculate the flow speed of the liquid flowing in the measurement tube 11 from the timing at which the heating resistance wire 12 a was momentarily heated and the timings at which the temperature detecting resistance wire 12 b and the temperature detecting resistance wire 12 c subsequently detect the temperature of the heated liquid. Also, the control substrate 20 can calculate the flow rate of the liquid from the obtained flow speed and the cross-sectional area of the measurement tube 11.

Although the temperature detecting resistance wires 12 b and 12 c are arranged downstream of the heating resistance wire 12 a in the liquid flowing direction in FIG. 8, they may be arranged otherwise.

For example, the temperature detecting resistance wire 12 b may be arranged upstream of the heating resistance wire 12 a in the liquid flowing direction, and the temperature detecting resistance wire 12 c may be arranged downstream of the heating resistance wire 12 a in the liquid flowing direction. The temperature distribution, to be created by the heating resistance wire 12 a depends on the flowing speed of the liquid, and the more the flowing speed increases, the more heat is conveyed downstream to raise the downstream temperature. The control substrate 20 can calculate the flow rate of the liquid from a difference between temperatures detected by the temperature detecting resistance wires 12 b and 12 c, and a cross-sectional area of the measurement tube 11.

As shown in FIG. 6 (the cross-sectional view taken along the line A-A in FIG. 3), the measurement tube 11 has an approximately circular cross section in a plane orthogonal to the axis X, where the sensor substrate 12 is bonded to the measurement tube 11. An outer circumferential surface of the measurement tube 11 has a flat surface 11 c where the detection surface 12 d of the sensor substrate 12 is arranged as opposed to the measurement tube 11.

On the other hand, as shown in FIG. 7 (a cross-sectional view taken along the line BB in FIG. 5(B)), the measurement tube 11 has a circular cross section in a plane orthogonal to the axis X, where the sensor substrate 12 is not bonded to the measurement tube 11.

As shown in FIGS. 5 and 6; the flat surface 11 c for the sensor substrate of the measurement tube 11 is arranged to be opposed to the detection surface 12 d of the sensor substrate 12. The flat surface 11 c for the sensor substrate and the detection surface 12 d axe bonded together with an adhesive.

Here, examples of the adhesive may include epoxy resin-based adhesives, UV curable resin-based adhesives, thermosetting-resin-based adhesives (thermosetting adhesives), and low melting point glasses.

As shown in FIG. 6, a distance D1 (a first distance) from the detection surface 12 d of the sensor substrate 12 to an inner circumferential surface 10 d of the internal flow passage 10 c is made shorter than a distance D2 (a second distance) from the top portion 11 d of the measurement tube 11 to the inner circumferential surface 10 d of the internal flow passage 10 c. This is for the purpose of improving thermal conductivity from the heating resistance wire 12 a to the liquid while improving temperature detecting property of the temperature detecting resistance wire 12 b and the temperature detecting resistance wire 12 c, by reducing the distance B1 from the detection surface 12 d of the sensor substrate 12 to the inner circumferential surface 10 d of the internal flow passage 10 c.

As shown In FIG. 6, the guide 14 is a metal member (e.g., made of stainless steel) that has a circular cross section and is provided with an opening portion 14 a at its top.

The guide 14 guides a pair of nuts 15 such that the nuts are coupled together. As shown in FIG. 3, the pair of nuts 15 are coupled together via the measurement tube 11, and the measurement tube 11 and the nuts 15 are fixed together by a filler 15 i that is charged into a recess 15 e (a first recess) and a filler 15 j that is charged into a recess 15 f (a second recess).

Accordingly, a space between the pair of nuts 15 in the direction of the axis X is fixed in the sensor unit 10 after manufacture shown in FIG. 3. On the other hand, the measurement tube 11 and the nuts 15 are not fixed together when the recesses 15 e and 15 f are not filled with the fillers 15 i and 15 j. With the measurement tube 11 and the nuts 15 not fixed together, the guide 14 is in contact at one end portion with a step portion 15 c of the inlet-side nut 15 a and at the other end portion with a step portion 15 d of the outlet-side nut 15 b to thereby maintain a constant distance between the pair of nuts 15.

Examples of the fillers 15 i and 15 j include those of epoxy resins, acrylic resins, and silicone resins.

The inlet-side body 16 receives the inlet 11 a of the measurement tube 11 and has inside a connection flow passage 16 a (a first connection flow passage) that has a circular cross section, as shown in FIG. 3. The inlet-side body 16 has external threads 16 b on an outer circumferential surface of its end portion facing the outlet 10 b.

The outlet-side body 17 receives the outlet 11 b of the measurement tube 11 and has inside a connection flow passage 17 a (a second connection flow passage) that has a circular cross section, as shown in FIG. 3. The cutlet-side body 17 has external threads 17 b on an outer circumferential surface of its end portion facing the inlet 10 a.

The inlet-side body 16 and the outlet-side body 17 are formed from a resin material with high corrosion resistance (e.g., PTFE: polytetrafluoroethylene).

The nuts 15 include the inlet-side nut 15 a attached to the inlet-side body 16 and the outlet-side nut 15 b attached to the outlet-side body 17.

As shown in FIG. 3, the inlet-side nut 15 a is a cylindrical member fitted along the outer circumferential surface of the measurement tube 11 to be closer to the outlet 11 b than the inlet-side body 16. The inlet-side nut 15 a has internal threads 15 g on an inner circumferential surface of its end portion facing the 10 a. Also, the outlet-side nut 15 b is a cylindrical member fitted along the outer circumferential surface of the measurement tube 11 to be closer to the inlet 11 a than the outlet-side body 17. The outlet-side nut 15 b has internal threads 15 h on an inner circumferential surface of its end portion facing the outlet 10 b.

The inlet-side nut 15 a is attached to the inlet-side body 16 as the internal threads 15 g of the inlet-side nut 15 a and the external threads 16 b of the inlet-side body 16 are fastened together. Similarly, the outlet-side nut 15 b is attached to the outlet-side body 17 as the internal threads 15 b of the outlet-side nut 15 b and the external threads 17 b of the outlet-side body 17 are fastened together.

The inlet-side nut 15 a has the recess 15 e (the first recess) that is recessed toward the inlet 10 a, at its end portion facing the outlet 10 b. As shown in FIG. 3, an inlet 11 a side end portion of the sensor substrate 12 and an inlet 11 a side end portion of the reinforcing plate 13 are inserted in the recess 15 e. Also, the recess 15 e is filled with the filler 15 i. The inlet 11 a side end portion of the sensor substrate 12 and the inlet 11 a side end portion of the reinforcing plate 13 are fixed to the inlet-side nut 15 a by the filler 15 i.

The outlet-side nut 15 b has the recess 15 f (the second recess) that is recessed toward the outlet 10 b, at its end portion facing the inlet 10 a. As shown in FIG. 3, an outlet 11 b side end portion of the sensor substrate 12 and an outlet 11 b side end portion of the reinforcing plate 13 are inserted in the recess 15 f Also, the recess 15 f is filled with the filler 15 j. The outlet 11 b side end portion of the sensor substrate 12 and the outlet 11 b side end portion of the reinforcing plate 13 are fixed to the outlet-side nut 15 b by the filler 15 j.

It is to be noted that although, the fillers are only charged, into the recesses 15 e and 15 f of the nuts 15 in the foregoing description, the sensor unit 10 may have other configurations. For example, the filler may be charged to fill up the entire region inside an inner circumference of the guide 14 in addition to the recesses 15 e and 15 f. In that case, the sensor substrate 12 and the reinforcing plate 13 are entirely fixed with the filler, and at the same time, the inlet-side nut 15 a and the outlet-side nut 15 b are fixed together by the filler.

The inlet-side ferrule 18 is a cylindrical resin member (e.g., formed of FTFE) that is inserted in between the outer circumferential surface of the measurement tube 11 and the inner circumferential surface of the outlet 10 b side end portion of the inlet-side body 16.

As shown in FIG. 4, an inlet 10 a side end portion of the inlet-side ferrule 18 has a tip portion 18 a at which the distance between an inner circumferential surface and an outer circumferential surface of the tip portion 18 a gradually decreases toward the inlet 10 a. The tip portion 18 a is inserted into a groove portion 16 c formed inside the inlet-side body 16 as it is inserted into the inlet-side body 16.

The outlet-side ferrule 19 is a cylindrical resin member (e.g., formed of PTFE) that is inserted in between the outer circumferential surface of the measurement tube 11 and an inner circumferential surface of the inlet 10 a side end portion of the outlet-side body 17.

As shown in FIG. 4, an outlet 10 b side end portion of the outlet-side ferrule 19 has a tip portion 19 a at which the distance between an inner circumferential surface and an outer circumferential surface gradually decreases toward the outlet 10 b. The tip portion 19 a is inserted into a groove portion 17 c formed inside the outlet-side body 17 as it is inserted into the outlet-side body 17.

As shown in FIG. 4, the groove portion 16 c of the inlet-side body 16 and the groove portion 17 c of the outlet-side body 17 are each formed to decrease in the groove width with the distance from the entrance of the groove to the bottom portion, The groove portion 16 c and the tip portion 18 a have the same length in the direction of the axis X, while the groove portion 16 c is sharper them the tip portion 18 a. Thus, in order to accommodate the tip portion 18 a in the groove portion 16 c without leaving any space, the tip portion 18 a needs to be deformed to conform to the shape of the groove portion 16 c.

Similarly, the groove portion 17 c and the tip portion 19 a have the same length, in the direction of the axis X, while the groove portion 17 c is sharper than the tip portion 19 a. Thus, in order to accommodate the tip portion 19 a in the groove portion 17 c without leaving any space, the tip portion 19 a needs to be deformed to conform to the shape of the groove portion 17 c.

The sensor unit 10 in the thermal flow meter 100 of the embodiment is assembled by fastening the internal threads 15 g of the inlet-side nut 15 a to the external threads 16 b of the inlet-side body 16 with the inlet 11 a of the measurement tube 11 and the inlet-side ferrule 18 inserted in the outlet 10 b side end portion of the inlet-side body 16, and fastening the internal threads 15 h of the outlet-side nut 15 b to the external threads 17 b of the outlet-side body 17 with the outlet 11 b of the measurement tube 11 and the outlet-side ferrule 19 inserted in the inlet 10 a side end portion of the outlet-side body 17.

The tip portion 18 a or the inlet-side ferrule 18 is forced into the groove portion 16 c of the inlet-side body 16 as the internal threads 15 g of the inlet-side nut 15 a become fastened to the external threads 16 b of the inlet-side body 16. Because the groove portion 16 c is sharper than the tip portion 18 a, the tip portion 18 a is gradually deformed as it is forced into the groove portion 16 c, and finally, deformed to be accommodated, in the groove portion 16 c without leaving any space.

The deformation of the tip portion 18 a forms a seal area between the outer circumferential surface of the measurement tube 11 and the inner circumferential surface of the inlet-side body 16, which reliably shuts off liquid that flows out through a location of connection of the connection flow passage 16 a with the internal flow passage 10 c so that the liquid never leaks to the outside. Moreover, the tip portion 18 a of the inlet-side ferrule 18 is positioned in the vicinity of the location of connection of the connection flow passage 16 a with the internal flow passage 10 c, thereby reducing an amount of liquid that flows out through the connection location to be remained (dead volume).

The inlet-side body 16 and the measurement tube 11 are connected such that they are arranged with their central axes coincident on the axis X. The connection structure enables the inlet side body 16 and the measurement tube 11 to be joined together without any steps between their inner walls, so that the flow of the liquid flowing inside will never be turbulent. Accordingly, the sensor substrate 12 can stably measure the flow rate of the liquid.

The fastening of the internal threads 15 g of the inlet-side nut 15 a and the external threads 16 b of the inlet-side body 16 is completed as an inlet 10 a side end of the inlet-side nut 15 a comes into contact with a projecting portion 16 d of the inlet-side body 16. The amount of deformation of the tip portion 18 a forced into the groove portion 16 c can be kept appropriate by arranging the projecting portion 16 d at an appropriate position.

The tip portion 19 a of the outlet-side ferrule 19 is forced into the groove portion 17 c of the outlet-side body 17 as the internal threads 15 h of the outlet-side nut 15 b become fastened to the external threads 17 b of the outlet-side body 17. Because the groove portion 17 c is sharper than the tip portion 19 a, the tip portion 19 a is gradually deformed as it is forced into the groove portion 17 c, and finally, deformed to be accommodated in the groove portion 17 c without leaving any space.

The deformation of the tip portion 19 a forms a seal area between the outer circumferential surface of the measurement tube 11 and the inner circumferential surface of the outlet-side body 17, which reliably shuts off liquid that flows out through a location of connection of the connection flow passage 17 a (the second connection flow passage) with the internal flow passage 10 c so that the liquid never leaks to the outside. Moreover, the tip portion 19 a of the outlet-side ferrule 19 is positioned in the vicinity of the location of connection of the connection flow passage 17 a with the internal flow passage 10 c, thereby reducing an amount of liquid that flows out through the connection location to be remained (dead volume).

The fastening of the internal threads 15 h of the outlet-side nut 15 b and the external threads 17 b of the outlet-side body 17 is completed as an outlet 10 b side end of the outlet-side nut 15 b comes into contact with a projecting portion 17 d of the outlet-side body 17. The amount of deformation of the tip portion 19 a forced into the groove portion 17 c can be kept appropriate by arranging the projecting portion 17 d at an appropriate position.

As shown in FIG. 5A, a distance L1 from the inlet 11 a of the measurement tube 11 to the middle portion of the sensor substrate 12 in the direction of the axis X is longer than a distance L2 from the outlet 11 b of the measurement tube 11 to the middle portion of the sensor substrate 12 in the direction of the axis X.

This is for the purpose of increasing the distance L1 from the location of connection of the connection flow passage 16 a with the inlet 11 a of the measurement tube 11 to the middle portion of the sensor substrate 12 in the direction of the axis X. Even if turbulence is generated in the liquid flow at the connection flow passage 16 a and the inlet 11 a of the measurement tube 11, the liquid flow can be stabilized before it reaches the middle portion of the sensor substrate 12 by increasing the distance L1.

As shown in FIGS. 3 and 4, the length of the inlet-side ferrule 18 along the axis X is made longer than the length of the outlet-side ferrule 19 along the axis X as the distance L1 is made longer than the distance L2.

This is for the purpose of positioning the tip portion 18 a of the inlet-side ferrule 18 in the vicinity of the location of connection of the connection flow passage 16 a with the inlet 11 a while positioning the tip portion 19 a of the outlet-side ferrule 19 in the vicinity of the location of connection of the connection flow passage 17 a with the outlet 11 b.

Next, a method of manufacturing the thermal, flow meter 100 of the embodiment will be described.

To begin with, a description will be given on a method for manufacturing the sensor unit 10 of the thermal flow meter 100.

First, the adhesive is applied to either one of the detection surface 12 d of the sensor substrate 12 and the flat surface 11 c for the sensor substrate of the measurement tube 11, and then, the sensor substrate 12 and the measurement tube 11 are arranged such that the detection surface 12 d and the fiat surface 11 c for the sensor substrate are in contact with each other via the adhesive, as shown in FIG. 5B.

Second, the measurement tube 11 with the sensor substrate 12 and the reinforcing plate 13 bonded thereto is mounted to a jig (not shown) to solidify the adhesive. The solidification of the adhesive renders the sensor substrate 12 and the reinforcing plate 13 secured to the measurement tube 11.

Here, when using a thermosetting-resin-based adhesive as the adhesive, the thermosetting-resin-based adhesive is solidified by mounting the measurement tube 11 with the sensor substrate 12 and the reinforcing plate 13 bonded thereto to the jig (not shown) and heating them.

Third, the inlet 11 a of the measurement tube 11 is inserted into the inlet-side nut 15 a, the inlet-side ferrule 18, and the inlet-side body 16 in this order. Also, the outlet 11 b of the measurement tube 11 is inserted into the outlet-side nut 15 b, the outlet-side ferrule 19, and the outlet-side body 17 in this order. Here, the inlet-side nut 15 a is attached to the inlet 10 a side end portion of the guide 14 and the outlet-side nut 15 b is attached to the outlet 10 b side end portion of the guide 14, so that the inlet-side nut 15 a and the outlet-side nut 15 b are retained, as appropriate.

Fourth, the internal threads 15 g of the inlet-side nut 15 a is fitted around the external threads 16 b of the inlet-side body 16, and fastened to the external threads 16 b until the inlet 10 a side end portion of the inlet-side nut 15 a comes into contact with the projecting portion 16 d. Also, the internal threads 15 h of the outlet-side nut 15 b is fitted around the external threads 17 b of the outlet-side body 17, and fastened to the external threads 17 b until the outlet 10 b side end portion of the outlet-side nut 15 b comes into contact with the projecting portion 17 d. Here, the tip portion 18 a of the inlet-side ferrule 18 and the tip portion 19 a of the outlet-side ferrule 19 are each deformed to form the seal areas.

Fifth, the recess 15 e at the outlet 10 b side end portion of the inlet-side nut 15 a is filled with the heated and softened filler 15 i, which is then cooled down until the filler 15 i solidifies. Similarly, the recess 15 f at the inlet 10 a side end portion of the outlet-side nut 15 b is filled with the heated and softened filler 15 j, which, is then cooled down until the filler 15 j solidifies.

The sensor unit 10 shown in FIG. 3 is manufactured in this way.

Sixth, the sensor unit 10 is inserted into the bottom case 30, and the stoppers 60 and 70 are inserted in between the bottom case 50 and the sensor unit 10. Thus, the sensor unit 10 is fixed to the bottom case 50.

Seventh, the control substrate 20 and the relay substrate 30 are attached to the upper case 40.

Finally, the upper case 40 is attached to the bottom case 50.

The thermal flow meter 100 of the embodiment is manufactured by the foregoing processes.

A description will be given to the operation and effect of the thermal flow meter 100 of the embodiment described above.

According to the thermal flow meter 100 of the embodiment, the inlet 11 a of the measurement tube 11 with the detection surface 12 d of the sensor substrate 12 bonded thereto is inserted into the inlet-side body 16 and connected to the connection flow passage 16 a formed inside the inlet-side body 16. Similarly, the outlet 11 b of the measurement tube 11 is inserted into the outlet-side body 17 and connected to the connection flow passage 17 a formed inside the outlet-side body 17.

When the external threads 16 b formed on the outer circumferential surface of the inlet-side body 16 are fastened to the internal threads 15 g formed on the inner circumferential surface of the inlet-side nut 15 a, the inlet 11 a side end portion of the measurement tube 11 is fixed, and at the same time, the tip portion 18 a of the cylindrical inlet-side ferrule 18 that is fitted around the outer circumferential surface of the measurement tube 11 is deformed to form the seal area. Similarly, when the external threads 17 b formed on the outer circumferential surface of the outlet-side body 17 are fastened to the internal threads 15 h formed on the inner circumferential surface of the outlet-side nut 15 b, the outlet 11 b side end portion of the measurement tube 11 is fixed, and at the same time, the tip portion 19 a of the cylindrical outlet-side ferrule 19 that is fitted around the outer circumferential surface of the measurement tube 11 is deformed to form the seal area.

The formation of the seal area on the inlet 11 a side of the measurement tube 11 prevents the liquid from flowing out through the location of connection of the internal flow passage 10 c of the measurement tube 11 with the connection flow passage 16 a of the inlet-side body 16. Similarly, the formation of the seal area on the outlet 11 b side of the measurement tube 11 prevents the liquid from flowing out through the location of connection of the internal flow passage 10 c of the measurement tube 11 with the connection flow passage 17 a of the outlet-side body 17.

Thus, according to the thermal flow meter 100 of the embodiment, there can be provided the thermal flow meter 100 in which the both end portions of the measurement tube 11 are securely fixed and which can suppress the leakage of the liquid at the both ends of the measurement tube 11.

According to the thermal flow meter 100 of the embodiment, the end portion of the sensor substrate 12 facing the inlet 11 a is fixed, by the filler 15 i, inside the recess 15 e of the inlet-side nut 15 a, and the end portion of the sensor substrate 12 facing the outlet 11 b is fixed, by the filler 15 j, inside the recess 15 f of the outlet-side nut 15 b. This can securely fix the both and portions of the measurement tube 11 to the inlet-side nut 15 a and the outlet-side nut 15 b.

According to the thermal flow meter 100 of the embodiment, the measurement tube 11 has on its outer circumferential surface the flat surface 11 c on which the detection surface 12 d of the sensor substrate 12 is oppositely positioned. The flat surface 11 c and the detection surface 12 d of the sensor substrate 12 are bonded together with the adhesive.

This can enhance the adhesiveness of the sensor substrate 12 to the measurement tube 11 while reducing the amount of the adhesive required for the adhesion.

According to the thermal flow meter 100 of the embodiment, the distance D1 from the detection surface 12 d of the sensor substrate 12 to the inner circumferential surface 10 d of the internal flow passage 10 c is shorter than the distance D2 from the top portion 11 d of the measurement tube 11 to the inner circumferential surface 10 d of the internal flow passage 10 c.

This can enhance the property of the heating resistance wire 12 a to heat the liquid inside the internal flow passage 10 c and the properties of the temperature detecting resistance wires 12 b and 12 c to detect the temperature of the liquid.

According to the thermal flow meter 100 of the embodiment, the sensor substrate 12 and the measurement tube 11 are made of glass. Using the sensor substrate 12 and the measurement tube 11 which have excellent heat resistance and less probability of deformation by heat, the flow rate measurement accuracy can be maintained regardless of changes in temperature. In addition, because the materials with the same thermal conductivity properties are bonded together, the adhesiveness of the sensor substrate 12 to the measurement tube 11 can be maintained regardless of changes in temperature.

{Second Embodiment}

Next, a thermal flow meter according to a second embodiment of the present disclosure will be described using FIGS. 9 and 10.

The second embodiment is a modification of the first embodiment, and is similar to the first embodiment unless otherwise described hereinafter.

In the sensor unit 10 of the thermal flow meter according to the first embodiment, the inlet-side nut 15 a has the recess 15 e that faces the outlet 10 b, and the outlet-side nut 15 b has the recess 15 f that faces the inlet 10 a.

On the other hand, in a sensor unit 10′ of the thermal flow meter according to the embodiment, an inlet-side nut 15′a has a recess 15′e formed by a guide 14′ that faces the outlet 10 b, and an outlet-side nut 15′b has a recess 15′f formed, by the guide 14′ that faces the inlet 10 a.

The guide 14′ guides the inlet-side nut 15′a and the outlet-side nut 15′b such that the nuts are coupled together. As shown in FIG. 9, the inlet-side nut 15′a and the outlet-side nut 15′b are coupled together via the measurement tube 11. The measurement tube 11 and the inlet-side nut 15′a are fixed together by the filler 15 i that is charged into the recess 15′e (the first recess). Also, the measurement tube 11 and the outlet-side nut 15′b are fixed together by the filler 15 j that is charged into the recess 15′f (the second recess).

The guide 14′ is a metal member (e.g., made of stainless steel) that has a circular cross section and is provided with an opening portion 14′a at its top.

As shown in FIG. 10, the guide 14′ does not open upwardly where it forms the recess 15′e and the recess 15′f, and has the opening portion 14′a only at the middle portion along the axis X.

It is to be -noted that the shape of the guide 14 of the first embodiment is illustrated by a broken line in FIG. 10 for comparison.

According to the embodiment, the inlet-side nut 15′a and the outlet-side nut 15′b are not specially shaped to have a recess at the end portion, and the recess 15′e and the recess 15′f can be formed using the guide 14′.

{Other Embodiments}

The present invention is not limited to the above embodiment, and modifications may be made as appropriate without departing from the scope of the present invention. 

The invention claimed is:
 1. A thermal flow meter comprising: a measurement tube including an inlet through which liquid enters and an outlet through which the liquid flowing from the inlet exits, and having an internal flow passage extending along an axis; a temperature detecting substrate having a heating resistance element and a temperature detecting resistance element formed on a detection surface thereof along the axis, the detection surface being bonded to the measurement tube along the axis; an inlet-side body which has inside a first connection flow passage and into which the inlet of the measurement tube is inserted; an outlet-side body which has inside a second connection flow passage and into which the outlet of the measurement tube is inserted, the outlet-side body being separately provided from the inlet-side body; a cylindrical inlet-side nut fitted along an outer circumferential surface of the measurement tube to be closer to the outlet than the inlet-side body, the inlet-side nut having on an inner circumferential surface thereof internal threads fastened to external threads formed on an outer circumferential surface of the inlet-side body; a cylindrical outlet-side nut fitted along the outer circumferential surface of the measurement tube to be closer to the inlet than the outlet-side body, the outlet-side nut having on an inner circumferential surface thereof internal threads fastened to external threads formed on an outer circumferential surface of the outlet-side body; an inlet-side ferrule of resin formed in a cylindrical shape and fitted between the outer circumferential surface of the measurement tube and an inner circumferential surface of an end portion of the inlet-side body facing the outlet, the inlet-side ferrule being deformed to form a seal area as the inlet-side nut is fastened to the inlet-side body; and an outlet-side ferrule of resin formed in a cylindrical shape and fitted between the outer circumferential surface of the measurement tube and an inner circumferential surface of an end portion of the outlet-side body facing the inlet, the outlet-side ferrule being deformed to form a seal area as the outlet-side nut is fastened to the outlet-side body, wherein: an end portion of the inlet-side nut facing the outlet comprises a first recess therein into which an end portion of the temperature detecting substrate facing the inlet is inserted; the end portion of the temperature detecting substrate facing the inlet is fixed to the inlet-side nut by a filler charged in the first recess; an end portion of the outlet-side nut facing the inlet comprises a second recess therein into which an end portion of the temperature detecting substrate facing the outlet is inserted; and the end portion of the temperature detecting substrate facing the outlet is fixed to the outlet-side nut by a filler charged in the second recess.
 2. The thermal flow meter according to claim 1, wherein the measurement tube comprises an outer circumferential surface comprising a flat surface, the detection surface of the temperature detecting substrate is oppositely positioned relative to the flat surface of the outer circumferential surface, and the flat surface and the detection surface of the temperature detecting substrate are bonded together with an adhesive.
 3. The thermal flow meter according to claim 1, wherein a first distance from the detection surface of the temperature detecting substrate to an inner circumferential surface of the internal flow passage is shorter than a second distance from a top portion of the measurement tube to the inner circumferential surface of the internal flow passage.
 4. The thermal flow meter according to claim 1, wherein the temperature detecting substrate and the measurement tube are made of glass. 